Metal roof system

ABSTRACT

The present invention generally relates to metal roofs. In one aspect, a method of placing a roof system over an existing low sloped roof is provided. The method includes measuring a slope of the existing low sloped roof to determine the location of irregularity points. Thereafter, at least one shim member is placed proximate each irregularity point and at other predetermined locations. Next, an airspace is formed between the existing low sloped roof and the roof system and then the roof system is operatively attached to the existing low sloped roof.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to metal roofs. More particularly, the invention relates to a metal roof system for use over an existing low slope modified bitumen, single ply rubber or built up roof.

2. Description of the Related Art

Many structures utilize low slope modified bitumen, single ply rubber or built up roofs to protect the interior of the structure from exposure to the elements, including sun, rain, snow, and the like. Modified bitumen, single ply rubber or built up roofs are utilized on metal, brick, wood, and other structures. Generally, the structure is built with interior columns that support a series of rafters or beams attached at the top of the columns. The roof rafters or beams are typically attached in a low-sloped manner with a ridge at the top to provide downward drainage. Spanning the rafters or beams is a wooden deck or a light gauge metal deck which is in turn covered with insulation and modified bitumen, single ply rubber or built up roofing. The decking generally runs perpendicular to the rafters or beams and is configured to be interconnected providing structural support for the overlying low slope modified bitumen, single ply rubber or built up roof. The low sloped roof usually consists of a layer of insulation board covered by either a multi-layer built up roof, a single ply rubber membrane or a modified bitumen membrane and are secured to a roof deck structure by nails, screws, clips, or other type fasteners. These low slope roofs find applications in many building constructions, such as commercial and industrial buildings.

Over time, due to wear and other factors, the existing low slope modified bitumen, single ply rubber or built up roof is either removed and replaced with another modified bitumen, single ply rubber or built up roof or re-roofed by placing a new metal roof on top of the existing low slope modified bitumen, single ply rubber or built up roof. Re-roofing of such roofs with metal is difficult since the reroofing operation typically requires additional support structure to add slope to the existing low sloped modified bitumen, single ply rubber or built up roof or insulation layers or possibly a wood layer to accept the new roof. The addition of a typical support structure makes this system difficult and expensive to apply effectively. Additionally, reroofing of low sloped roofs with metal is typically hard to effectively weatherproof due to the slope of the roof which results in a less then optimum downward drainage. Furthermore, the metal panels in the new roof are subject to considerable movement together with the building due to the expansion and contraction of the panels by heat, cold, wind, etc. making it extremely difficult to provide a satisfactory weatherproof seal along the seams and at the fastener locations since over time the panels and their seams tend to become loose and create a potential leak path.

A need therefore exists for a reliable and a weatherproof metal roof system for use to re-roof an existing low slope modified bitumen, single ply rubber or built up roof without adding slope.

SUMMARY OF THE INVENTION

The present invention generally relates to a metal roof system. In one aspect, a method of placing a roof system over an existing low slope modified bitumen, single ply rubber or built up roof is provided. The method includes measuring a slope plane of the existing low slope modified bitumen, single ply rubber or built up roof to determine the location of irregularity points. Thereafter, at least one shim member is placed proximate each low irregularity point and at other predetermined locations. Next, an air space is formed between the existing low sloped roof and the roof system and then the roof system is operatively attached to the existing low sloped roof.

In another aspect, a method of placing a roof system over an existing low sloped roof is provided. The method includes placing at least one shim member proximate each irregularity point on the existing low sloped roof and at other predetermined locations. The method further includes reducing the heat transfer from the roof system to a building or structure below by forming an air space between the roof system and the existing low sloped roof. Further, the method includes operatively attaching the roof system to the existing low sloped roof.

In yet another aspect, a method of placing a roof system over an existing low sloped roof is provided. The method includes measuring a slope plane of the existing low sloped roof to determine the location of irregularity points and then placing at least one shim member proximate each low irregularity point and at other predetermined locations. The method also includes directing the thermal movement of the roof system by employing a plurality of fixed and floating clips at predetermined locations between the roof system and the existing low sloped roof and then operatively attaching the roof system to the existing low sloped roof.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

FIG. 1 is a view illustrating a sidewall arrangement of a roof system in accordance with the present invention.

FIG. 2 is a view illustrating a headwall arrangement and a curb arrangement of the roof system in accordance with the present invention.

FIG. 3 is a view illustrating the headwall arrangement.

FIG. 4 is a view illustrating the curb arrangement.

DETAILED DESCRIPTION

The present invention generally relates to a metal roof system for use on an existing low sloped modified bitumen, single ply rubber or built up roof. The metal roof system is comprised of clips, shims, roof panels, and other components. Prior to installing the metal roof system, the existing low sloped modified bitumen, single ply rubber or built up roof must be examined to determine if it is suitable for a retrofit. For example, the existing roof decking is examined to determine if the decking is capable of holding fasteners. Additionally, the structure of the existing roof is examined to determine if the structure is capable of holding additional weight. After the existing low sloped roof has been completely examined and has met certain criteria, the metal roof system of the present invention may be employed in accordance with the method described herein. To better understand the novelty of the apparatus of the present invention and the methods of use thereof, reference is hereafter made to the accompanying drawings.

FIG. 1 is a view illustrating a sidewall arrangement 150 of a roof system 100 in accordance with the present invention. Generally, the sidewall arrangement 150 is a portion of the roof system 100 adjacent a wall 155 on an existing roof 10. The sidewall arrangement is constructed of various components to ensure that there is a weatherproof relationship between the wall 155 and the roof system 100.

The sidewall arrangement 150 includes a plurality of shims 165 or bearing plates positioned at predetermined locations along on top of the existing roof 10. Prior to positioning the shims 165, the slope of the existing roof 10 is measured by a level device (not shown). The level device is used to determine the amount of shimming that will be required to make the roof system 100 straight and true. Next, the shims 165 are used to fill low spots or irregularities and other predetermined locations on the existing roof 10 to ensure that the roof system 100 is substantially without dips which typically hold water. It should be noted that a plurality of shims may be employed at any one location without departing from principles of the present invention. In one embodiment, the shims 165 are constructed from a plastic or composite material. Additionally, the shims 165 or bearing plates are used to increase the contact surface area between a clip 120 and the existing roof 10. Furthermore, the shims 165 are used to create an airspace 135 between the existing roof 10 and the roof system 100.

The airspace 135 is generally used as insulation to reduce the amount of heat transferred from the roof system 100 through the existing roof 10 into the building or structure below (not shown). In reducing the amount of heat transferred into the building or structure below the roof system 100, the energy required to heat or cool the building or structure is subsequently reduced. In one embodiment, a radiant barrier may be disposed in the airspace 135 to further reduce the amount of heat transfer between the roof system 100 and the building or structure below. It should be understood, however, that any form of insulation may be employed in the airspace 135 without departing from principles of the present invention

The sidewall arrangement 150 further includes a plurality of clips 120 positioned on top of the shims 165. The clips 120 are secured to the existing roof 10 by a plurality of fasteners 130. The primary function of the clips 120 is to secure the roof system 100 to the existing roof 10. More particularly, the clips 120 provide a means of supporting a roof panel 125 and holding new roof panels together. The clips 120 may be a fixed clip which is secured at one location or a floating clip which is capable of moving a predetermined distance. The floating clip allows the panel 125 to move as the panel 125 expands or contracts due to heat, cold, etc. Therefore, the placement of the fixed and floating clips at predetermined locations on the existing roof controls the direct thermal movement of the roof system 100. In one embodiment, the fixed clips will be used in the middle area or top area of the roof system 100 and all other clips will be floating clips installed in such a manner where a sliding mechanism is in the center of the clip allowing the panel to move in either direction. Another function of the clips 120 adjacent the wall 155 is to support a sidewall cleat 110.

As illustrated in FIG. 1, the sidewall cleat 110 is attached both to a seam of the panel 125 and to the clips 120 by a fastening member 170. Typically, a tape seal 140 is disposed between the panel 125 and the sidewall cleat 110 to create a watertight sealing relationship therebetween. The tape seal 140 is generally an elastomeric material that is capable of forming a fluid seal between two members. The sidewall cleat 110 or extension member is used to raise the perimeter of the roof system 100 along the wall 155 to ensure a weatherproof arrangement between the roof system 100 and the building or structure below. The sidewall arrangement 150 also includes a sidewall trim 105 that extends downwardly over the sidewall cleat 110. The sidewall trim 105 is used to direct particles, such as water, toward the roof panel 125. It should be noted that the sidewall trim 105 is not operatively attached to the roof panel 125, thereby allowing the roof panel 125 to expand or contract without affecting the sidewall trim 105. Additionally, the panel 125 is sloped in the direction indicated by arrow 115 to facilitate the downward drainage of the particles, such as water.

FIG. 2 is a view illustrating a headwall arrangement 200 and a curb arrangement 250 of the roof system 100 in accordance with the present invention. The headwall arrangement 200 is generally used to create a weatherproof relationship between a head wall 245 and the roof system 100, as illustrated in FIGS. 2 and 3. The curb arrangement 250 is generally used to create a weatherproof relationship between a penetration, such as an AC unit or a sky light (not shown), and the roof system 100, as illustrated in FIGS. 2 and 4. For convenience, the components in the sidewall arrangement 150 that are similar to the components in the headwall arrangement 200 and the curb arrangement 250 will be labeled with the same number indicator.

As illustrated in FIG. 3, the headwall arrangement 200 includes a plurality of shim members 165 disposed on top of the existing roof 10. Typically, a roof panel 225 that adjoins the head wall 245 will have extra shims 165 to support the top of the panel. Thereafter, a strip member 215 is placed on top of the shim members 165 adjacent the headwall 245. In one embodiment, the strip member 215 is a 6″ wide, 16 gauge piece of sheet metal. A lower zee 210 is positioned inside the panel 225 and operatively attached to the strip member 215 by a plurality of fasteners 170. The tape seal 140 is disposed between the strip member 215 and the panel 225 to create a fluid tight relationship therebetween. It should be noted that lower zee 210 and the strip member 215 are not attached to the existing roof 10, thereby allowing the panel 225 to expand or contract without affecting the headwall arrangement 200. Additionally, panel 225 is sloped in the direction indicated by arrow 230 to facilitate the downward drainage of the particles, such as water.

The roof panel 225 and other main roof panels are typically continuous along their entire length from the ridge or headwall to the eave with no end laps. In one embodiment, the roof panel 225 and other roof panels (not shown) in the roof system 100 have different panel widths to ensure that the last panel seam lands at a predetermined distance from a penetration or a wall. Additionally, in another embodiment, the roof panel 225 and other panels in the roof system 100 have a vertical seam arrangement, thereby allowing versatility and more complex roof geometry.

As shown, an upper zee 205 is attached to an upper end of the lower zee 210 by a plurality of fasteners 170. Additionally, the tape seal 140 is disposed between the upper and lower zees 205, 210 to create a fluid tight relationship therebetween. The upper zee 205 is used to raise the perimeter of the roof system 100 along the headwall 245 or ridge to ensure a weatherproof arrangement between the roof system 100 and the building or structure below. The headwall arrangement 200 also includes a headwall trim 220 operatively attached to the upper zee 205 by fasteners 170. The headwall trim 220 is used to direct particles, such as water, toward the roof panel 225. Typically, a seal member (not shown) is employed between the headwall trim 220 and the headwall 245 to create a sealing relationship therebetween.

Referring back to FIG. 2, the curb arrangement 250 is positioned adjacent the headwall arrangement 200. It should be understood, however, that the curb arrangement 250 may be positioned at any location on the roof system 100, without departing from principles of the present invention. As illustrated, a panel 255 on the curb arrangement 250 is raised in relation to the panel 225 and run substantially perpendicular to panel 225, thereby allowing the panel 255 to direct particles, such as water, into the panel 225. Additionally, panel 255 is sloped in the direction indicated by arrow 260 to facilitate the downward drainage of the particles.

As illustrated in FIG. 4, shim 165 is placed on top of the existing roof 10. A clip 280 is placed on top of the shim 165 and secured to the existing roof 10 by fastener 130. Disposed on the upper end of the panel seam is a side cleat 275. The side cleat 275 is used to raise the perimeter of the roof system 100 along curb arrangement 250 to ensure a weatherproof arrangement between the roof system 100 and the building or structure below. Additionally, the side cleat 275 is adjacent a structural zee member 270 disposed on top of the shim 165. A transverse panel trim 265 is disposed adjacent the zee member 270. The transverse panel 255 is secured to the transverse panel trim 265 by fasteners 170. The transverse panel trim 265 and the zee member 270 are constructed and arranged to allow the panel 225 to expand or contract without affecting the curb arrangement 250. Additionally, the tape seal 140 is typically disposed between the members of the curb arrangement 250 to ensure a fluid tight relationship therebetween.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. 

1. A method of placing a roof system over an existing low sloped roof comprising: measuring a slope plane of the existing low sloped roof to determine the location of irregularity points; placing at least one shim member proximate each low irregularity point and at other predetermined locations; forming an airspace between the existing low sloped roof and the roof system; and operatively attaching the roof system to the existing low sloped roof.
 2. The method of claim 1, further including securing a clip member on top of the at least one shim member to attach a plurality of roof panels of the roof system to the existing low sloped roof.
 3. The method of claim 2, wherein the plurality of roof panels are continuous from a ridge to an eave of the roof system.
 4. The method of claim 2, wherein the plurality of roof panels are constructed and arranged to ensure the last roof panel lands at a predetermined distance from a penetration or a wall.
 5. The method of claim 2, further including raising the perimeter of the roof system to create a weatherproof relationship between the roof system and a building or a structure below.
 6. The method of claim 5, wherein an extension member is placed on top of a panel seam of the roof panel to raise the perimeter of the roof system.
 7. The method of claim 6, further including creating a sealing relationship between the extension member and the panel seam.
 8. The method of claim 1, further including reducing the heat transfer between the roof system and a building or a structure below by utilizing the air space.
 9. The method of claim 8, further including placing a radiant barrier in the airspace.
 10. The method of claim 1, further including running a plurality of roof panels on an uphill side of a large penetration, wherein the roof panels are perpendicular to the slope.
 11. The method of claim 10, further including raising the plurality of roof panels on the uphill side of the large penetration.
 12. A method of placing a roof system over an existing low sloped roof comprising: placing at least one shim member proximate each low irregularity point on the existing low sloped roof and at other predetermined locations; reducing the heat transfer from the roof system to a building or structure below by forming an air space between the roof system and the existing low sloped roof; and operatively attaching the roof system to the existing low sloped roof.
 13. The method of claim 12, further including directing the thermal movement of the roof system by employing a plurality of fixed and floating clips between the roof system and the existing low sloped roof.
 14. The method of claim 12, further including raising the perimeter of the roof system to create a weatherproof relationship between the roof system and a building or a structure below.
 15. The method of claim 12, wherein the roof system includes a plurality of roof panels which are continuous from a ridge to an eave.
 16. The method of claim 15, wherein the plurality of roof panels are constructed and arranged to ensure the last roof panel lands at a predetermined distance from a penetration or a wall.
 17. A method of placing a roof system over an existing low sloped roof comprising: measuring a slope plane of the existing low sloped roof to determine the location of irregularity points; placing at least one shim member proximate each low irregularity point and at other predetermined locations; directing the thermal movement of the roof system by employing a plurality of fixed and floating clips at predetermined locations between the roof system and the existing low sloped roof; and operatively attaching the roof system to the existing low sloped roof.
 18. The method of claim 17, further including forming an air space between the existing low sloped roof and the roof system.
 19. The method of claim 17, wherein the roof system includes a plurality of roof panels which are continuous from a ridge to an eave.
 20. A member for use with a roof system, the member comprising a plate member constructed and arranged to raise the roof system relative to an existing low sloped roof and to fill a low irregularity point on the existing low sloped roof. 